Innovative technologies for the production of large-formats, decoration and firing

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1 Innovative technologies for the production of large-formats, decoration and firing Andrea Morozzi SACMI November 27 th, 2015

2 2 Large Ceramic Formats: evolution of presses t t t t 20x20 4u. 0,16 m 2 30x30 4u. 0,36 m 2 60x60 2u. 0,72 m 2 100x200 1u. 2,00 m 2

3 3 Nowadays SACMI offers several different technologies suitable for large formats PH 10000

4 4 PH Max size 120 x 180 cm Thickness 3 30 mm Production up to sqm/day

5 5 CONTINUA line with PH10000 press Max size 120 x 180 cm Thickness 3 30 mm Production up to sqm/day Very high value products

6 6 New CONTINUA+ line Max size 160 x (unlimited) cm Thickness 3 20 mm Production up to sqm/day High value products

7 7 New CONTINUA+ line Introduced in 2012 (GranitiFiandre Italy) Presently 15 lines installed/sold (7 Italy, 8 World) There is NO final press, since PCR+ applies the total force by means a special steel belt Real thickness from 3 to 20 mm (fired) Max format 160 x (theoretically unlimited) cm Great variety of effects (even in the body and surface) Very high throughput (up to sqm/day) Decoration with extra-large digital printers Structured surface with special steel belt

8 New CONTINUA+ line The Continua+ line does not require any foundation; all machines are simply placed over the ground The perfect compaction all over the front

8 8 New CONTINUA+ line The Continua+ line does not require any foundation; all machines are simply placed over the ground The perfect compaction all over the front ensures low scraps (less 3%) Very low energy consumption (- 80% with respect a PH press) The PCR+ press is very silent No dust generation, no environmental pollution

9 9 Continua+ allows easy realization of full body, multi-layer and structured effects suitable for different product destinations Savings of expensive raw materials Aesthetical stratifications Thermal insulation (with foamed ceramic) Structured surfaces

10 Heart of the Continua+ technology is the new PCR+ high pressure belt compatter (SACMI s patent) The high pressure roller system plus a special high resistance steel

10 10 Heart of the Continua+ technology is the new PCR+ high pressure belt compatter (SACMI s patent) The high pressure roller system plus a special high resistance steel belt allows to reach definitive compacting action onto the powders The continuous action of PCR+ allows tremendous throughput of perfectly pressed slabs New CONTINUA+ line

11 In order to produce structured surfaces, the pressing steel belt can be covered by a special resin layer, reproducing the desired relief The layer, seamless, is applied by means a special

11 11 In order to produce structured surfaces, the pressing steel belt can be covered by a special resin layer, reproducing the desired relief The layer, seamless, is applied by means a special process (SACMI s patent) The quality of the relief, the shining of the surface are strength points of this exclusive process The change of the structured belt requires 30 minutes New CONTINUA+ line

12 12 Official video CONTINUA+ promo video

13 13

14 14 DECORATION LINE DDD PCR DHD DIGITAL POWDER APPLICATION STRUCTURED BELT DIGITAL WET DECORATION

15 15 Powder application DDD Powder decoration PCR 2000 Compaction APB-0 Base body

200 m FEEDING MATERIALS SPRAY DRIED POWDERS SPRAY DRIED

16 16 DDD Digital Dry Decoration Hopper Vibrating plates Width range: mm Resolution: 100 dpi Graphic length: up to 200 m FEEDING MATERIALS SPRAY DRIED POWDERS SPRAY DRIED GLAZES GRAINS FLAKES Moisture 2,5 5% Moisture 2 3% 3 mm max 3 mm max

17 17 DDD Digital Dry Decoration

18 18 STRUCTURED BELT COATED STEEL BY UV RESIN Width range: mm Belt length: 7500 mm Relief depth: 1mm

19 19 DHD High Definition Decoration Large formats 1200 mm up to 8 colourbars DHD mm 1500 or 1600 mm DHD mm resolution: 360 dpi

20 20 PRODUCT DESIGN LINE Set-up DIGITAL GRAPHICS DEVELOPMENT DDD FILE STRUCTURE FILE DHD FILE

21 21 APB-0 + APB-00 (base body + secondlayer)

22 22 DRY DECORATION - (DDD color 1)

23 23 DRY DECORATION - (DDD color 2)

24 24 PRESSING WITH STRUCTURED BELT - ( PCR2000 )

25 25 INK-JET DECORATION - ( DHD )

26 26 FINAL PRODUCT -( travertino )

27 27 PRODUCT EXAMPLES

28 28 PRODUCT EXAMPLES Travertino Base powder DHD (4 barre colore) Travertino Base powder DDD (2 grafiche) DHD (4 barre colore)

29 29 PRODUCT EXAMPLES Travertino grey Base powder APB-M (mix powders second layer) DHD (4 colour bars) Marble «Pavonazzetto» Base powder DDD (2 graphics) DHD (4 colour bars)

30 30 EKO kiln C C C RR RLW RF

31 The EKO kiln advantage The firing of very large ceramic slabs represents a challenging technical issue Due

leading to distortions and, in some case, breakages The EKO kiln, recently introduced by SACMI, approaches the

kiln: longitudinal fumes flow new EKO kiln: transversal fumes flow To realize this, the kiln is equipped with

31 31 The EKO kiln advantage The firing of very large ceramic slabs represents a challenging technical issue Due to uneven temperature distribution inside the kiln tunnel, big slabs could suffer differential deformation, leading to distortions and, in some case, breakages The EKO kiln, recently introduced by SACMI, approaches the issue in a revolutionary way, changing the flow direction of the fumes inside the kiln TILES TILES traditional kiln: longitudinal fumes flow new EKO kiln: transversal fumes flow To realize this, the kiln is equipped with auto recuperative burners, that allows the transversal recirculation of the fumes at very high flame speed (up 100 m/s)

32 32 Every EKO burner has its own chimney that evacuates the relative fumes portion, after a high efficiency pre-heating of the combustion air. The selective fumes extraction allows also a more effective depuration (particularly F, Cl and heavy metals). The transversal flow permits a better kiln regulation, even in case of product loss or delays. As a consequence, the EKO kiln performance in term of final product quality reaches top levels. The EKO kiln advantage

33 33 Conclusions The Continua+ technology recently introduced in the market allows tremendous throughput production of very high quality level ceramic slabs. Due to its exclusive pressing method, Continua+ ensures great homogeneity in the product density, determining good stability and low scraps level. Thanks to the particular restraint method, the pressing action is independent with respect the front width, allowing great format flexibility and different product size modules, always maximizing the productivity. The continuous belt pressing process ensures the maximum freedom in aesthetical effects, giving any possibility in term of dry or wet decoration, particularly with digital decorating machines. The very low energy consumption, joined with no pollution and no dust generation, makes the Continua+ process the best available technology in the ceramic field for the environment. Joining high productivity and beautiful aesthetical effect, the Continua+ is the future ceramic technology of the next decades.

34 34 Thank you for your attention

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